Suzuki 2 Strokes

I split the cases to fit the rubber dam in the gearbox of my 72 T500 and I used an electric impact wrench to undo the large nuts that hold the clutch drum and sprocket in place - this seemed to work fine. I don't have access to the special tool shown on the Suzuki workshop manual which hold these items in place to allow you to torque them up correctly when you assemble the engine again. If I used the impact wrench again to assemble these items, would this be sufficient or is there another way of doing this if you don't have the special tool - Thanks

I don't know how a 500 is made, but on a 550 you can stuff a rag between the primary gear (the one on the back of the clutch basket) and the crank shaft gear. No special tool required.

No, that works for the primary drive gear, but not for the clutch. Primary drives the outer clutch basket, but the clutch hub has the nut (and will spin freely, as there are no clutch plates to hold it).

I used an impact wrench to remove, and to reinstall, the clutch nut. Also used a new fold-over washer/retainer on both the clutch nut and primary gear nut.

You need a tool to hold the clutch basket. Motion Pro sells a ViceGrip with long bent tines that sometimes works. The best tool is made from a couple of thick clutch plates and a steel handle like these:



The best tool to hold two gears is a third gear or at least a small segment from one.

Did mine a few weeks ago, with no problem. Had marked sprocket with correction fluid and used impact driver to tighten back to same point. Tightened clutch housing with torque wrench, was easy to "jam" and hold. No special tools used.
Ian

Hi
MytoolsUk make a superb clutch holding tool for the T500, It also fits the T250.
I supplied Jason with the dimensions.
It holds both the clutch centre & basket at the same time.
Regards Bri e

They also sell the tool via eBay.
http://www.ebay.com/itm/SUZUKI-T250-T50 ... 0902331181

I have a spare unused clutch holding tool (18 tooth) if anyone wants one. $32 US + shipping at cost.

It's one of these: http://www.ebay.com/itm/SUZUKI-T250-T50 ... 0902331181" onclick="window.open(this.href);return false;

Cheers

PM sent

Fritz500 wrote:I have a spare unused clutch holding tool (18 tooth) if anyone wants one. $32 US + shipping at cost.

It's one of these: http://www.ebay.com/itm/SUZUKI-T250-T50 ... 0902331181" onclick="window.open(this.href);return false;" onclick="window.open(this.href);return false;

Cheers

jabcb wrote:They also sell the tool via eBay.
http://www.ebay.com/itm/SUZUKI-T250-T50 ... 0902331181

I tried one (maybe not this one). The one I bought, didn't fit.

Impact wrench works fine.

How didn't it fit??

It was an EBC tool (just looked a few minutes ago). It was supposed to fit T500. right diameter, wrong size/spacing for the outer hub.

Mine fitted very snugly. It is made to quite fine tolerances. There are two types - one with 18 fingers and one with 9. I have used mine several times and it made things a lot easier. I usually make my own jigs and special tools when I can but sometimes I treat myself...

Cheers

Fritz500 wrote:Mine fitted very snugly. It is made to quite fine tolerances. There are two types - one with 18 fingers and one with 9. I have used mine several times and it made things a lot easier. I usually make my own jigs and special tools when I can but sometimes I treat myself...

Cheers

HI Think that should read "There are two types - one with 18 fingers and one with 12."?
The 18 finger one fits the T250-T350-T500 & probably GT500.
The 12 finger one fits the GT250 including the X7 250.
Not sure which one if any would fit the GT380 - GT550 - GT750 ( may be they also shared clutch baskets?)
Regards Bri e

locobuilderbri wrote:

Fritz500 wrote:Mine fitted very snugly. It is made to quite fine tolerances. There are two types - one with 18 fingers and one with 9. I have used mine several times and it made things a lot easier. I usually make my own jigs and special tools when I can but sometimes I treat myself...

Cheers

HI Think that should read "There are two types - one with 18 fingers and one with 12."?
The 18 finger one fits the T250-T350-T500 & probably GT500.
The 12 finger one fits the GT250 including the X7 250.
Not sure which one if any would fit the GT380 - GT550 - GT750 ( may be they also shared clutch baskets?)
Regards Bri e

Yes, sorry my mistake. The 18 finger one (the one I used) is for the pre GT500 models and the other one has 12 fingers not 9.


Cheers